As the world grapples with the urgent need to address climate change, transitioning to a net-zero economy has become a global priority. Governments, businesses, and individuals are increasingly committing to reducing greenhouse gas (GHG) emissions to achieve net-zero status by 2050. While clean energy, transportation, and industrial decarbonization often dominate the conversation, the role of materials in this transition is equally critical. The materials we use—whether in construction, manufacturing, or everyday products—are deeply tied to carbon emissions. By shifting toward sustainable materials, we can reduce the environmental impact of our industries and move closer to a net-zero future.

This article explores the importance of a materials transition, how it can help us reach our climate goals, and what changes need to occur across industries to make this vision a reality.

The Carbon Footprint of Materials

Materials play a fundamental role in modern society. Everything from the buildings we live and work in, to the vehicles we drive and the products we use daily relies on materials that are often carbon-intensive to produce and maintain. Key sectors that depend heavily on materials like steel, concrete, aluminium, and plastics contribute significantly to global carbon emissions. Indeed, the production, use, and eventual disposal of these four industrial materials contribute to nearly a quarter of all global carbon dioxide (CO₂) emissions.

For instance, cement production alone accounts for approximately 8% of global CO₂ emissions, while steel manufacturing contributes about 7%. These industries rely on energy-intensive processes that not only consume vast amounts of resources but also emit large quantities of CO₂. Plastics, derived from fossil fuels, are another major source of emissions, contributing to both GHG emissions and environmental pollution.

Addressing these challenges requires a comprehensive shift in how we produce, use, and recycle materials: a so-called materials transition.

What is a Materials Transition and Why is it Important?

Materials transition refers to the production of materials that put less strain on the environment. It encompasses enhancing efficiency through innovative material choices, exploring alternatives to traditional materials, and prioritizing solutions that promote circularity—such as recycling, reusing, and minimizing waste throughout the material life cycle. A materials transition is crucial for a myriad of reasons.

Reducing Carbon Emissions at the Source 

Traditional materials like concrete, steel, and plastics are deeply embedded in global supply chains. Reducing their carbon footprint is essential to achieving net-zero targets. Transitioning to more sustainable alternatives – such as polymer concrete, mass timber, fiberglass, green steel (produced using hydrogen), and post-consumer recyclates (PCR) plastics – can substantially lower emissions.  Innovations in material science are enabling the development of alternative materials that require less energy to produce and emit fewer pollutants, helping industries decarbonize their operations.

Energy Efficiency and Sustainable Production 

A materials transition also requires rethinking how materials are produced, including the integration of real-time manufacturing process monitoring. Innovative artificial intelligence (AI)-powered technologies can halt production if target material properties aren’t met, saving valuable time, energy, and costs. Energy-efficient manufacturing processes and circular economy models, which focus on reducing waste and reusing resources, are key to minimizing the environmental impact of material production. For example, recycled steel uses significantly less energy compared to producing new steel from iron ore. Similarly, using industrial byproducts in concrete, such as fly ash or slag, can reduce the carbon intensity of construction projects.

Improved Durability and Life Cycle Management 

The sustainability of materials is not only about how they’re produced but also about their durability and end-of-life management. Extending materials’ life cycle through better design, maintenance, and recycling can further reduce emissions. The European Union (EU) is supporting this through a new directive – the “Right to Repair” – which focuses on making goods more easily repairable for consumers. Materials that are designed for disassembly, recycling, or reuse help create a circular economy, where fewer resources are extracted from the earth and less waste ends up in landfills. This not only reduces environmental damage but also limits the demand for new, carbon-intensive materials.

Impact on the Built Environment 

The built environment—including buildings, infrastructure, and transportation systems—is one of the largest consumers of materials and a significant contributor to GHG emissions. Retrofitting existing buildings with energy-efficient materials, such as fiberglass, polymer concrete, engineered wood, and mass timber products can dramatically reduce structures’ operational carbon footprint. Additionally, embracing prefabricated materials and modular construction techniques can reduce waste and improve energy efficiency in construction.

Innovations Driving the Materials Transition

Several promising innovations are accelerating the shift toward sustainable materials:

Green Steel

Traditional steel production relies heavily on coal-powered blast furnaces. However, green steel, produced using renewable hydrogen instead of coal, offers a carbon-free alternative. Companies like SSAB and ArcelorMittal are already making strides in producing green steel, significantly reducing emissions from one of the most carbon-intensive industries.

Polymer Concrete

Concrete is an indispensable material in construction, but its production is environmentally damaging. Innovations such as polymer concrete – which uses polymer binders in place of traditional cement – and alternative binders like geopolymer cement are helping lower concrete’s carbon footprint. These materials offer even stronger, and more durable options that significantly reduce emissions, paving the way for more sustainable construction practices.

PCR Plastics

By reprocessing plastic waste into new products, PCR plastics reduce CO₂ emissions in two significant ways: decreasing the demand for energy-intensive virgin plastic production and diverting waste from landfills. Innovative recycling methods now enable the use of PCR plastics even in automotive safety components, cutting CO₂ footprint by up to 45% while also meeting high-level visual quality standards.

Recycling and Circular Economy Models

Recycling and reusing materials play a key role in reducing the need for new production. Advances in chemical recycling – which breaks down materials at a molecular level – and closed-loop production systems are helping industries embrace circular economy principles. For example, companies are investing in technologies that allow for the infinite recycling of plastics, reducing reliance on virgin materials.

Challenges and Opportunities

While the materials transition offers immense potential for reducing emissions, it also presents challenges. The high upfront costs of developing and deploying new technologies, the inertia of traditional industries, and the lack of widespread regulatory support can slow progress. However, these obstacles also present opportunities for innovation, new business models, policy reform, and investment in sustainable infrastructure.

Governments and businesses must collaborate to create policies that encourage to minimize materials environmental impact. Carbon pricing, incentives for green materials, stricter emissions regulations, and legislations promoting products longevity can all drive significant change. Additionally, consumer demand for eco-friendly products can push industries to adopt sustainable practices more quickly.

Conclusion: Building a Net-Zero Future with Sustainable Materials

A successful transition to a net-zero future depends on rethinking how we produce, use, and reuse materials. By embracing innovative, low-carbon materials, circular economy principles and cutting-edge engineering technologies based on data and simulation models, industries can significantly reduce their carbon footprint while continuing to meet the growing demand for infrastructure and products. The materials transition is not only essential for protecting the planet, but it also provides crucial raw materials independence and represents a significant business opportunity.

As we strive toward net-zero goals, the materials and ethical choices we make today will shape the future we build tomorrow.

To learn more about Altair’s material solutions, visit https://altair.com/materials.